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United States Patent |
5,649,409
|
Gujer
,   et al.
|
July 22, 1997
|
Apparatus for manufacturing flexible containers
Abstract
An apparatus for manufacturing flexible containers of the type comprising
particulate material located between two flexible web members (16, 17),
the apparatus comprising a first feed means suitably in the form of one or
more drive roller assemblies (13, 43) for advancing a first flexible web
member through the apparatus, a metering means suitably in the form of a
metering roller (12) having recesses (84) on its peripheral face to
accomodate the particulate material and to deposit the particulate
material onto the first flexible web member, second feed means suitably in
the form of a roller assembly (13, 43) to pass a second flexible web
member over the first flexible web member containing the particulate
material, and sealing means suitably comprising a roller assembly (13)
having one of the rollers including heated zones (94) or portions along
its external surface such that when the first and second web members pass
between the rollers the web members are sealed together along areas
corresponding to contact of the web members with the heated zones or
portions. In this manner, there can be formed flexible containers or
sachets containing particulate material such as super absorbant polymer
which can be immersed in water and subsequently frozen to be used as a
heat exchange pad.
Inventors:
|
Gujer; Heinz (Ardeer, AU);
Tintor; Branko (Melbourne, AU)
|
Assignee:
|
Thermarite Pty. Ltd. (Queensland, AU)
|
Appl. No.:
|
341296 |
Filed:
|
November 15, 1994 |
Current U.S. Class: |
53/461; 53/285; 53/286; 53/463 |
Intern'l Class: |
B65B 011/08 |
Field of Search: |
53/461,463,285,286
|
References Cited
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|
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|
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| |
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| |
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| |
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| |
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| |
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| |
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| |
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| |
Other References
The International Preliminary Examination Report for PCT/AU90/00544.
|
Primary Examiner: Seidleck; James J.
Assistant Examiner: Williamson; Michael A.
Attorney, Agent or Firm: Russell; Dean W., Labbee; Michael F.
Kilpatrick Stockton LLP
Parent Case Text
This application is a continuation of co-pending application Ser. No.
08/155,121, filed Nov. 19, 1993, which is a continuation (divisional) of
application Ser. No. 07/720,421 (U.S. Pat. No. 5,265,401), filed Jun. 25,
1991, now which is the national phase of application No. PCT/AU90/00544,
filed Nov. 13, 1990, published as WO91/07319, May 30, 1991, which claims
priority to Australian application No. PJ7373, filed Nov. 14, 1989.
Claims
We claim:
1. A method for making a flexible container containing particulate material
comprising the steps of:
a. advancing a first flexible web member with a first feed means;
b. metering the particulate material onto one side of the first flexible
web member with a metering means;
c. passing a second flexible web member over the first flexible web member
with a second feed means subsequent to the particulate material being
metered thereon;
d. sealing the first and second flexible web members together with a
sealing means to form the flexible container containing the particulate
material;
e. perforating with a plurality of cutting means the sealed portions of the
first and second flexible web members but not portions of the first and
second flexible web members that are not sealed together; and
f. vibrating the sealed first and second web members with a vibrating means
to facilitate even distribution of the particulate material in the formed
flexible container.
2. A method according to claim 1 in which the step of perforating portions
of the first and second web members comprises:
a. providing a plurality of cutters mounted along an axle;
b. adjusting the position of at least one of the plurality of cutters along
the axle; and
c. contacting the portions of the first and second web members to be
perforated with at least one of the plurality of cutters.
3. A method for making a flexible container comprising the steps of:
a. advancing a first flexible web member with a first feed means;
b. metering particles of a water absorbing polymer onto one side of the
first flexible web member with a metering means;
c. passing a second flexible web member over the first flexible web member
with a second feed means subsequent to the particles being metered
thereon, at least one of the first and second flexible web members being a
water permeable non-woven fabric;
d. sealing the first and second flexible web members together with a
sealing means to form the flexible container containing the particles;
e. perforating with a plurality of cutting means the sealed portions of the
first and second flexible web members but not portions of the first and
second flexible web members that are not sealed together; and
f. vibrating the sealed first and second web members with a vibrating means
to facilitate even distribution of the particles in the formed flexible
container.
Description
FIELD OF INVENTION
This invention relates to an apparatus for manufacturing flexible
containers and especially for manufacturing flexible containers comprising
particulate material located between two flexible web members and a
flexible container manufactured by such an apparatus.
BACKGROUND ART
Flexible containers such as containers made of fabric or mesh material are
usually formed from a single sheet of material which is folded to define
edges and then sealed along those edges. Normally, one edge is left
unsealed through which material can be inserted into the container
whereafter that edge is also sealed. This process however is cumbersome
and does not easily lend itself to inexpensive manufacture of such
containers.
It is an object of the invention to provide an apparatus for manufacturing
flexible containers which may overcome the abovementioned disadvantages.
DISCLOSURE OF INVENTION
In one form, the invention resides in an apparatus for manufacturing a
flexible container comprising particulate material located between two
flexible web members, said apparatus comprising
first feed means for advancing a first flexible web member through said
apparatus,
metering means for metering the particulate material onto one side of said
first flexible web member,
second feed means for passing a second flexible web member over said first
flexible web member subsequent to the particulate material being metered
thereon, and,
sealing means for sealing said first and second flexible web members
together to form the flexible container containing the particulate
material.
The first feed means suitably includes one or more drive roller assemblies
for advancing the first flexible web member through the apparatus. The
first feed means may also include one or more guide members to assist in
the advancement of the first flexible web member.
The or each drive roller assemblies may comprise a pair of opposed rollers
between which the first flexible web member can pass. Suitably, one of
the, pair of rollers is a driven roller and the other of the pair of
rollers is a free roller. The pair of opposed rollers may be disposed such
that one roller extends substantially above the second roller and it is
preferred that in this configuration the upper roller is a free roller and
the lower roller is a driven roller.
The spacing between the pair of opposed rollers may be varied to allow web
members of various thickness to pass between the rollers. Suitably, the
driven roller is fixed and the free roller is movable towards and away
from the driven roller. The free roller may be freely movable towards and
away from the driven roller or may be actuated by an actuating means.
The actuating means may be mechanically, hydraulically or pneumatically
powered to move the free roller away from and/or towards the drive roller.
Preferably, the actuating means comprises a ram.
The first feed means suitably comprises at least two drive roller
assemblies spaced from each other.
The guide members may comprise elongate tubes having a smooth external
radial surface along which the first flexible web member may advance. The
guide members can assist in guiding the web member to, from, or between
the various rollers in the apparatus. The guide members are suitably fixed
in position and do not rotate.
The metering means suitably comprises a metering roller. The metering
roller is suitably driven about its longitudinal axis. The metering roller
may have an outer radial periphery provided with at least one recess to
accept the particulate material. Preferably, the periphery is provided
with a plurality of such recesses. The recesses may be regularly spaced
along the periphery of the roller and in substantially linear alignment
and may also be spaced about the periphery of the roller. The recesses may
comprise single recesses or groups of recesses.
The first flexible web member suitably contacts the metering roller after
the particulate material has been added thereto and may be maintained in
contact with the metering roller upon rotation thereof to retain the
particulate material within the recesses until the web is in a
substantially horizontal position at which time the web suitably separates
from the metering roller and contains the particulate material on one side
of the web.
The first feed means suitably assists in maintaining the first flexible web
member in contact with the metering roller.
The second feed means suitably comprises some or all of the drive roller
assemblies of the first feed means as described above. The second feed
means may also include one or more guide members. The second feed means
may comprise a drive roller assembly as described above which assembly is
located downstream from the metering means. The second feed means assists
in passing a second flexible web member over the first flexible web member
such that the particulate material is located between the two web members.
The sealing means preferably comprises a heating step to heat seal the
first and second web members together. Suitably, the sealing means
comprises a heated roller assembly. The heated roller assembly may
comprise a pair of rollers between which the first and second web members
pass. Preferably, one of the pair of rollers is heated and this roller can
be internally heated.
Suitably, the heated roller assembly as described above comprises one of
the drive roller assemblies of the first feed means. It is preferred that
the heated roller is a driven roller and that the other roller is a free
roller.
The heated roller may include heated zones or portions along its external
radial surface such that when the first and second web members pass
between the rollers, the web members are sealed together along areas
corresponding to contact of the web members with the heated zones or
portions.
The heated zones or portions are suitably formed by providing the heated
roller with spaced recesses with the surface of the roller extending
between adjacent recesses forming the heated zones or portions.
Preferably, the heated roller comprises a plurality of recesses spaced
along the roller and in longitudinal alignment and also about the
periphery of the roller. This provides a regular array of heated zones or
portions which in use seal the two web members together along a plurality
of positions thereby forming a plurality of flexible containers or pockets
in the web.
The apparatus may further include a storage chamber for storing the
particulate material to be used in association with the metering means.
Suitably, the storage chamber comprises a hopper. The hopper may include an
outlet-which extends at least partially along the metering roller.
Preferably, the outlet is in sliding contact with the roller and may be
located vertically above the roller such that as the metering roller
rotates across the outlet, particulate material passes into the recesses
on the metering roller. The outlet may be in association with a wiper
blade to ensure that the particulate material passes into the recesses.
Suitably, the outlet is integrally formed with the hopper and is
positioned at a lower portion of the hopper.
The apparatus may further include perforating means to perforate the sealed
first and second web members subsequent to passing through the sealing
means. The perforating means may include at least one cutter to cut the
web members either in a continuous manner to provide separate flexible
containers or in a non-continuous manner to provide lines of weakness into
the sealed web members thereby allowing the various different flexible
containers to be torn from the remaining portion of the sealed web
members.
The perforating means may comprise a plurality of cutters which in use are
spaced across the web members to cut the members as they pass by the
cutters. The cutters are preferably spaced across the web members such
that the cuts are made along the sealed portions and not through the
portions of the web members that are not sealed together.
The cutters may be mounted to a common elongate support and are suitably
axially adjustable therealong. Preferably, each cutter is also adjustable
between an operating cutting position and a raised free position. The
cutters may comprise a wheel or disk having a peripheral continuous
cutting edge or peripheral spaced cutting edges or projections.
The perforating means may perforate the web members in the direction of
travel of the web through the apparatus and/or transversly across the
direction of travel.
The apparatus may further include a take-up roller upon which the sealed
web members may be wound. Preferably, the take-up roller is a driven
roller.
The various drive rollers are suitably driven from a common drive means.
The drive means may comprise a electric motor. The drive rollers may be
coupled to the drive means by conventional drive chains and/or drive
belts. Suitably, the drive means drives the metering roller through a
drive chain and sprocket assembly and other drive rollers are driven by
the metering roller again through conventional drive chain and/or drive
belt assemblies.
The apparatus may further include a vibrating means to vibrate the web
members subsequent to being sealed. The vibrating means may comprise a
vibrating plate which extends across the respective web member and
vibrates it as it passes along the vibrating plate. The vibrating plate
facilitates an even dispersion of the particulate material within its
formed flexible container.
The first and second flexible web members are suitably formed from the same
material. Preferably, the web members comprise an non-woven fabric which
is suitably water permeable. The non-woven fabric is preferably formed
from bicomponent filaments having a central core and a surround of a
meltable material. The meltable material may comprise a thermoplastic
polymer such as polyethylene. Alternatively the meltable material may
comprise a heat melt adhesive. The core suitably comprises a polyester. In
this manner the two web members can be sealed by heat joining the two
layers of fabric. A suitable fabric is an Eleves fabric 40 cm (S0503 WDO)
available from C. ITOH & CO.
In another form the invention resides in a flexible container containing
particulate material, said container comprising first and second flexible
web members joined together to define at least one compartment containing
the particulate material, each said web member comprising a non woven
fabric formed from bicomponent filaments having a central core and a
surround of meltable material. The non woven fabric may be as described
above.
The particulate material may comprise a water absorbing compound or
composition. Suitably, the particulate material comprises a water
absorbing polymer. A preferred water absorbing polymer is a cross-linked
sodium polyacrylate super absorbing polymer.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by reference to the following
description of one preferred embodiment as illustrated by the accompanying
drawings in which
FIG. 1 is a side view of an apparatus for manufacturing flexible containers
according to a preferred embodiment.
FIG. 2 is a side view of the opposite side of the apparatus of FIG. 1.
FIG. 3 is a front view of the apparatus of FIGS. 1 and 2.
FIGS. 4A and 4B are views of the metering roller according to a preferred
embodiment.
FIG. 4A1 is an enlarged cross-section of a metering roller recess.
FIG. 5 is a view of the heated roller according to a preferred embodiment.
FIG. 6 is a view of the flexible containers formed by the apparatus
according to an embodiment of the invention.
BEST METHOD FOR CARRYING OUT THE INVENTION
Referring to FIGS. 1 to 3, there is disclosed an embodiment of the
apparatus for manufacturing flexible containers.
The apparatus comprises a main support frame 11 for supporting the various
components of the apparatus, a metering means in the form of a metering
roller 12, a sealing means in the form of a heated roller assembly 13, and
first and second feed means in the form of various rollers as shall be
described in more detail below.
A first flexible web member 16 suitably in the form of a roll of web
material can be supported on a roller 13A which is supported for rotation
by suitable bearings 14 located on each end of roller 13A. Bearings 14
(only one shown in FIG. 1) are supported by an angle bracket 15 one leg of
which is secured to main support frame 11. In this manner, roller 13A is
supported at a position spaced from main frame 11 which allows easy access
to the roller for mounting a roll of web material. Furthermore, with the
web material mounted to roller 13A, the material will not contact the main
support frame and this arrangement allows large rolls of web material to
be supported by the roller.
The first flexible web member 16 (shown in phantom) is advanced through the
apparatus by a series of drive roller assemblies which shall be described
in greater detail below.
A second flexible web member 17 (shown in phantom) can be stored on a roll
which is supported by roller 18. Roller 18 is supported for rotation by
suitable bearings 19 supporting ends of roller 18. Roller 18 is in this
manner mounted between opposed frame members 20, 21 of main support frame
11. Roller 18 includes tapered plugs 22, 23 which are supported on roller
18 and locate on each axial face of a roll of flexible material mounted to
roller 18 to prevent axial displacement of the roll. Roller 13A can also
be provided with similar plugs (not shown). It should be appreciated that
the position of the rollers 13A and 18 is for convenience only and various
other positions can be envisaged.
Metering roller 12 includes a generally cylindrical body supported at each
end by bearings within bearing houses 24 (only one shown) which are
mounted to frame members 27, 28 of main support frame 11.
The metering roller is more clearly disclosed in FIGS. 4A, 4B and will be
more clearly described below. The metering roller includes a plurality of
recesses on its surface to accommodate particulate material.
A hopper 29 is positioned generally above metering roller 12 and comprises
an inlet 30 in an upper portion of the hopper and an outlet 31 at a lower
portion of the hopper.
Outlet 31 comprises an elongate opening extending along the length of
metering roller 12 and is in sliding contact with the metering roller. The
outlet 31 may be associated with a wiper blade to ensure that the
particulate material is only received within the recesses on the metering
roller (not shown). Outlet 31 is located substantially vertically above
metering roller 12 which is the most convenient place to allow the
particulate material to contact the metering roller.
Thus, upon rotation of metering roller 12 in the direction indicated by the
arrow of FIG. 1, the recesses will pass across outlet 31 and particulate
material will flow into the recesses from hopper 29.
Guide members 52, 33 are provided to guide the first flexible web member 16
towards metering roller 12. Guide members 31, 32 comprise cylindrical
tubes having a smooth outer surface over which the first flexible web
member can slide. The guide members extend between opposed frame members
34, 35 of the main support frame 11 and are rigidly mounted thereto. Guide
member 31 locates immediately behind outlet 31 such that the first
flexible web member 16 is guided over metering roller 12 immediately after
particulate material is passed into the recesses as will be described in
greater detail below.
Immediately below metering roller 12 is provided a positioning roller 34A
which aides in maintaining flexible web member 16 in contact with the
.periphery of metering roller 12 in the area between guide member 33 and
positioning roller 34A. Positioning roller 34A is movable towards and away
from metering roller 12 by an hydraulic or pneumatic ram 34B thereby
allowing web members of varying thickness to pass between positioning
roller 34A and metering roller 12.
A first drive roller assembly 13 is located adjacent metering roller 12
such that the flexible web member passes from metering roller 12 to the
first drive roller assembly 13. Assembly 13 comprises a pair of opposed
rollers 36, 37 which are supported for rotation about their ends by
suitable bearings within bearing housings. Roller 36 is located vertically
above roller 37. Roller 37 is supported by its pair of bearing housings
which are secured to opposed frame members 38, 39. Upper roller 36 is
movable towards and away from roller 37 and can be actuated between these
positions by a pair of hydraulic or pneumatic rams 40, 41 located at
opposed ends of roller 36.
Roller 37 is a heated roller and is electrically heated internally. A
thermostat 42 regulates the temperature of roller 37.
Upper roller 36 is not heated but normally becomes hot because of its
contact or close proximity to heated roller 37.
Heated roller 37 includes a plurality of spaced recesses as more clearly
shown with reference to FIG. 5. This configuration results in a pattern of
heated zones or portions corresponding to the surface of the roller
extending between the recesses.
First flexible web member 16 passes from metering roller 12 to first drive
roller assembly 13 and passes between lower heated roller 37 and upper
roller 36. As well, a second flexible web member 17 can pass from roller
18, around upper roller 36 and between roller 36 and heated roller 37. In
this manner, the second flexible web member 17 is caused to pass over
flexible web member 16 and the two web members are sealed together as they
pass between rollers 37 and 36, the sealing areas corresponding to contact
of the web members with the heated zones or portions of heated roller 37.
It can be seen that in this embodiment, the first drive roller assembly 13
functions as the sealing means and also as the second feed means in
passing the second flexible web member over the first flexible web member.
A second drive roller assembly 43 is located downstream from the first
drive roller assembly 35 such that the sealed web members 16, 17 pass from
the first drive roller assembly 35 towards the second drive roller
assembly 43.
Assembly 43 again comprises a lower roller 44 and an upper roller 45. The
ends of lower roller 44 are mounted to bearing housings 45, 46 (only one
shown in FIG. 1) which are secured to opposed frame members 38, 39. Lower
roller 44 is fixed while upper roller 45 is movable towards and away from
roller 44. The ends of upper roller 45 are mounted in bearing housings 47,
48 which are connected to hydraulic or pneumatic rams 49, 50 to move upper
roller 45 towards and away from lower roller 44. Lower roller 44 is also
formed with recesses in a manner similar to heated roller 37.
A counting wheel 51 is located adjacent second drive roll assembly 43 and
is suitably mounted to frame members 20 and 21.
A perforating means 52 in the form of a plurality of cutters 55-57 is
located adjacent the second drive roller assembly 43 to cut or perforate
the sealed web members. The cutters are mounted to an axle 53 (as most
clearly shown in FIG. 3) which is mounted adjacent its ends to a platform
54. Cutters 55-57 are axially adjustable along axle 53 and can be secured
against axial displacements by a locking screw or similar means (not
shown). Cutters 55-57 can be moved between an upper free position (as
shown in phantom in FIG. 1 and FIG. 2) and a lower cutting position. It
should be appreciated that the number of cutters can vary and only three
have been shown in the embodiment.
As the sealed web material passes along cutters 55-57 they can be
continuously cut into separate strips or intermittently cut to form lines
of weakness, depending on the type of cutters used.
Adjacent the perforating means 52 is located a vibrator 58 comprising an
eccentric generator 59 and a vibrating plate 60 over which the sealed web
passes. Vibrator 58 facilitates an even distribution of the particulate
material in each formed pocket or sachet within the web.
A take-up roller 61 is located at the end of platform 52 to take-up the web
as it passes through the apparatus. A free floating roller 62 is located
adjacent roller 61 to provide tension and correct feeding of the web to
take-up roller 61. A pair of hydraulic or pneumatic rams 63, 64 are
located on each end of platform 54 and include an arcuate shoe 65 (only
one shown) to limit the free travel of roller 62.
The various rollers are driven by a drive means in the form of an electric
motor 66 located in a lower part of main frame 11 and supported thereby.
Electric motor 66 includes a gearbox 67 having a drive sprocket 68. Drive
sprocket 68 is connected to a sprocket 69 on one end of metering roller 12
through drive chain 70. A tensioner 71 is located between sprocket 68 and
69 to tension drive chain 70.
The other end of metering roller 12 (see FIG. 2) is provided with sprocket
72. Sprockets 73, 74 (74 not shown) are also located on complimentary end
faces of heated roller 37 and roller 44 and these rollers are driven by
metering roller 12 through a drive chain 74A extending about the
sprockets. Drive chain 74A also extends about a return sprocket 75 and a
tensioning sprocket 76.
Take-up roller 61 is driven by a drive chain 76 extending about a sprocket
on take-up roller 61 and a sprocket on adjacent roller 77 which itself is
driven by roller 44 through drive belt 78 extending about pulleys 79, 80
located on second roller 44 and adjacent roller 77 respectively.
In this manner, electric motor 66 can drive the various rollers although it
should be appreciated that the series of pulleys, sprockets, drive chains
and drive belts are only in the configuration provided in the embodiment
for purposes of convenience and other variations can easily be envisaged.
A control box 81 controls the supply of power to electric motor 66 and the
various hydraulic or pneumatic rams.
FIGS. 4A and 4B disclose the metering roller 12 in more detail. Metering
roller 12 comprises a cylindrical body 82 and extensions 83 which extend
into bearing housings to support metering roller 12 for rotation. The
outer surface of cylindrical surface 82 is provided with a plurality of
recesses 84 which are spaced long the cylindrical body and in linear
alignment with each other and also spaced about cylindrical body 82.
Each recess comprises an essentially circular mouth 85 and a tapered rear
portion 86 tapering to a point.
FIG. 4B illustrates an alternative arrangement of recesses 84. In this
alternative arrangement, groups of recesses 87 are spaced along
cylindrical body 82 and in linear alignment with each other and also about
cylindrical body 82. Each group of recesses 87 comprises a number of
recesses 88 in a substantially oval pattern.
As the recesses accommodate the particulate material, it can be seen that
the arrangement as illustrated in FIG. 4A will result in a web member
being provided with discrete individual mounds of particulate material
while the arrangement as illustrated in FIG. 4B will result in groups of
particulate material being provided on one side of the web member.
FIG. 5 discloses an embodiment of heated roller 37 in greater detail.
Heated roller 37 includes end portions 90, 91 which extend into bearing
housings (not shown) to rotatably support roller 37. Roller 37 includes a
plurality of spaced recesses 92 formed on its outer surface by attaching a
framework 93 to the outer surface of heated roller 37. In this manner,
there are formed heated zones 94 corresponding to the configuration of
framework 93 which is in a heat exchange relationship with heated roller
37. Upon passage of the first and second flexible web members between
heated roller 37 and upper roller 36, the web members are heat sealed
together corresponding to the arrangement of framework 93. Thus, it can be
seen that this particular roller will heat seal the two web members
together to form eight separate flexible containers across the web
members.
FIG. 6 discloses a sample of the web members subsequent to passing through
heated roller 37 and roller 36. It can be seen that the web members have
been sealed together along 94 corresponding to the heated zones of roller
37. Particulate material 95 was added by metering roller 12 with the
arrangement of metering roller 12 and heated roller 37 being such that the
webs are heat sealed together around the particulate material 95 to
provide individual flexible containers or pockets.
The operation of the apparatus shall now be described with reference to
FIGS. 1 to 3. A first flexible web member 16 is passed from roller 13A
over guide 32 and around guide 31 and is fed about metering roller 12 and
between metering roller 12 and positioning roller 34A. Upon rotation of
metering roller 12, the recesses in the surface of the roller pass across
hopper outlet 31 and particulate material flows into the recesses. The
particulate material is then prevented from exiting the recesses upon
further rotation of metering roller 12 by virtue of the first flexible web
member 16 being pressed against the surface of metering roller 12.
Subsequent to passing along positioning roller 34A, the first web member
16 now adopts a substantially horizontal position and the particulate
material can pass from the recesses onto an upper surface of the web
member. At this time, the web member will have located on an upper surface
thereon metered quantities of the particulate material at spaced intervals
corresponding to the spacing and configuration of the recesses on the
metering roller. A second flexible web member 17 is passed from roller 19
about upper roller 36 and passes between roller 36 and heated roller 37
concurrently with first flexible web member 16. The second flexible web
member is caused to be positioned over the first flexible web member and
the web members are sealed together along areas corresponding to the
heated zones of the heated roller 37.
The periphery of heated roller 37 is configured such that the heated zones
extend around the metered quantities of particulate material such that
upon passage between rollers 36 and 37, the two web members are sealed
together around the metered quantities of particulate material to form the
flexible containers or pockets. The sealed material is passed between
rollers 44 and 45 which function to facilitate movement of the web
material through the apparatus. The cutters 55-57 either cut or introduce
lines of weakness through the sealed web members and the cutters are
spaced along axle 53 such that the cuts are made along the sealed joints
of the two webs. Thereafter, the material is vibrated to evenly disperse
the polymer in the formed pocket or sachet and the web is then wound over
take-up roller 61.
The heated roller can operate at a temperature of about 180.degree. C.
In an alternative, a transverse splitter can be positioned on platform 54
to cut the sealed web material to form the web into sheets or pads instead
of the web being wound around take-up roller 61.
Thus, it can be seen that the apparatus is suitable for producing flexible
containers and the finished product manufactured by the apparatus
according to the preferred embodiment has metered quantities of material
such as super absorbent polymer each located in a discrete pocket or
sachet which pockets are of a size as to permit the amount of polymer
therein to absorb a predetermined quantity of water.
It can also be seen that the apparatus can manufacture flexible containers
of any desired size or shape and the flexible containers can extend across
the full width of the web members or several flexible containers may be
formed in the web members. These various shapes and sizes may be formed by
varying the configuration of the heated zones or portions on the heated
roller of the sealing means.
The flexible containers thereby formed can be either individually cut from
the remainder of the roll by the perforating means or a separate cutter or
splitter to form individual flexible containers. Alternatively, a number
of separate flexible containers may be cut from the remainder of the roll.
The article produced by the invention is particularly suitable for
absorbing liquid such as water that can be taken up by the water absorbing
polymer. Thus, when the pad is placed into water, the water can migrate
through the fabric and be absorbed by the polymer. The absorption will
continue until the pressure exerted on the polymer by the walls of the
pocket is effectively equal to the internal pressure in the polymer grains
at which time no further water can be absorbed.
Therefore, the water absorbing ability of the pads can be varied by the
amount of super absorbent polymer added to each pad and the interior
volume of the pad.
If the pad is removed from the water and excess water removed by shaking,
the pad will be effectively dry to the touch as the absorbent powder
removes wetness from the fabric surface. The pad can then be frozen to
provide a heat exchange medium.
Further advantages of the particular pad are that condensation does not
form on the pad as any water condensed by heat exchange is absorbed by the
polymer. Furthermore, upon absorbing heat, the frozen pad thaws out but
water is not lost from the pad as it is retained by the super absorbant
polymer.
It should be appreciated that the above embodiment is by way of
exemplification of the invention only and the various other changes and
modifications can be made to the invention without departing from the
spirit and scope thereof as defined in the appended claims.
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